Net Seals: innovation and growth with Modula WMS

Efficient warehouse management is one of the most complex and crucial challenges for any company, regardless of industry.

For example, of the various activities, inventory is a critical asset; non-optimised inventory management can result in high costs, lost opportunities and client dissatisfaction. In this context, the adoption of warehouse management system (WMS) software integrated with the company management system proves to be a strategic choice of great importance. Not only does a WMS automate and optimise warehouse operations, when it is perfectly integrated with the management system, it also provides a comprehensive, real-time view of the entire production and logistics cycle.

Based on companies’ varying needs, at Modula we have designed several WMS software packages that not only monitor and track the operations of automated storage solutions, but also those of manual warehouses: a very important aspect, given that one of the biggest concerns is the sudden need to completely transform a warehouse from manual to automated.

Our clients’ various testimonials show that the exact opposite is the case: the adoption of a Modula automated solution is very gradual. Indeed, new machinery can be installed and purchased – years later – and interconnections can be maintained at all times, enabling it to communicate with the company management system.

Automated solutions tailored to every requirement: the Net Seals case

Net Seals is a benchmark company in the production and distribution of industrial seals. Founded to provide high-performance sealing solutions, the company stands out for its technological innovation, product quality and client focus. With a global presence, Net Seals serves clients in various industries, including automotive, petrochemical, the food industry and many more. The company offers a wide range of seals for different applications, including mechanical, piston, rod and static seals.

Transition to warehouse automation

To improve understanding of the decision made by Net Seals – and the resulting benefits – we spoke directly with the CEO, Andrea Rani, who explained the journey his company has been on towards automation.

“In 15 years”, said Andrea Rani, “we have gone from the Stone Age to a technological evolution that will soon also include the use of robots. We purchased our first Modulas in 2014. It was a challenge, I had heard about automated warehouses, but I had to understand how to exploit these technologies within our business. Our company spaces are long and narrow, filled with traditional shelving, with all the operators going up and down the stairs to complete orders. After the installation of the first three units, the benefits encountered were so great that, in my head, the intention to achieve a fully automated warehouse within 10 years took shape, and I can now say that I have almost succeeded”.

Warehouse management system evolution

Before the arrival of Modula vertical lift modules, the warehouse was completely manual, managed by an custom WMS that only needed to communicate with the ERP.

With the purchase of the first three Modula warehouses in 2014 and another three in 2016, the performance of the warehouse management software proved too low to manage both the manual warehouse and a fleet of six Modula units.

In the two-year period between 2018 and 2020, when another 15 Modula units were purchased, it therefore became almost essential to update the WMS: by that point, the server was too old and there was a need for more powerful hardware for the 21 Modula units to communicate both with the manual warehouse and the company management system, and also with the new Net Seals e-commerce.

Implementation of Modula WMS Premium

This combination of factors led Net Seals to choose and install the Modula WMS software Premium package. As soon as it had been installed, it became possible to monitor everything that was happening inside the warehouse, including the activity of the Modula warehouses, until then considered by the management system as simple shelving.

Currently, the Modula WMS software manages:

• Terminals
• Mobile picking app
• Put to light
• Manual warehouse

It isn’t only about product traceability: the location of various SKUs can be checked at any time, the frequency of movements can be analysed and the related data – including batch and serial numbers, production dates, product expiry and ageing – can be managed smartly.

Modula WMS software makes it possible to identify which operator has had access to a specific tray, to manage tray slotting into compartments and to monitor both volumes of warehouse occupancy and the degree of saturation. Finally, installed alongside the Modula WMS is Modula Cloud, the portal that collects and processes information and activities from the warehouses, very useful for diagnosing issues in case of malfunctions.

Benefits of automation with Modula WMS software

In 2020, the fleet of Modula machines was enriched with another 19 automated warehouses: a total of 40 were reached and, for the first time, 19 clients were managed with a single Modula WMS.

In concrete terms, this means that the entire Net Seals warehouse process, from the arrival of the order on the website or at the sales office to the preparation of orders, is managed by a single licence for the warehouse software.

Thanks to the Modula WMS software, the entire warehouse – the company now has 42 vertical lift modules – is connected by a single direct line to communicate with the company management system and receives orders directly from the website.

It is clear that Net Seals has achieved significant advantages in terms of operational efficiency, reduction of picking times and improvement of product traceability. The full automation of the warehouse has made it possible to reduce the margins of error, optimise space and respond promptly to market demand, ensuring a high level of client satisfaction.

The experience at Net Seals demonstrates how the adoption of a warehouse management system such as Modula WMS, combined with a gradual and well-planned transition process, can lead to outstanding results. The company has not only managed to modernise its warehouse, it has also created a highly flexible and scalable structure, ready to support future growth and innovation. 

Investing in advanced technologies such as Modula WMS is therefore proving to be a winning strategy for all companies aiming to improve their competitiveness and efficiently manage their logistics operations.